Foamable Reinforcement Element for Cavity Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hollow structural components face challenges in maintaining stability, strength, corrosion resistance, and noise insulation due to their design, which complicates reinforcement and sealing, especially in hard-to-reach areas.
Innovation Solution
A method involving a foamable material with a fiber material coated in a hardening adhesive composition is used, where the foamable material is thermally foamed to press the fiber material against the cavity walls before the adhesive cures, providing reinforcement, sealing, and noise-damping properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If hollow structural components are used to reduce weight and material requirements, then weight and material consumption are reduced, but stability, strength, and corrosion resistance deteriorate
Solution Approach 1:
The invention uses composite materials consisting of a foamable material (polymer matrix) combined with fiber materials (reinforcement phase) and curing adhesive composition. The fiber material is embedded in the foamable material, creating a composite structure that provides both the weight reduction benefits of hollow components and the strength enhancement through the fiber-reinforced composite structure.
2Strength
If reinforcement elements are inserted into hollow components to improve mechanical properties, then strength is improved, but device complexity and difficulty of installation increase
Solution Approach 1:
The invention merges multiple functions into a single reinforcement element: the foamable material provides structural reinforcement and filling, the fiber material provides tensile strength, and the curing adhesive composition provides bonding to the cavity walls. This integration eliminates the need for separate reinforcement components and simplifies installation to a single process step.
Solution Approach 2:
The invention utilizes parameter changes in the foamable material's physical state, transitioning from a liquid or semi-liquid injected state to an expanded foam state. This phase change allows the material to flow into cavity corners and hard-to-reach areas, then expand to provide uniform reinforcement throughout the cavity space.
3Reliability
If traditional sealing methods are used in hollow components, then sealing is achieved, but adhesion and reliability in hard-to-reach areas deteriorate
Solution Approach 1:
The curing adhesive composition is designed to self-bond to the cavity walls through chemical adhesion. As the foamable material expands and presses against the cavity walls, the adhesive composition cures in situ, creating self-bonding seals that automatically adapt to the cavity geometry without requiring external sealing tools or complex installation procedures.
4Ease of operation
If structural foams are used in hard-to-reach areas, then accessibility is improved, but mechanical properties such as shear strength and adhesion deteriorate
Solution Approach 1:
The invention creates a composite structure where the foamable material (providing accessibility and filling hard-to-reach areas) is combined with fiber materials (providing tensile strength) and curing adhesive composition (providing bond strength). The fiber reinforcement compensates for the weaker mechanical properties of the foamable material alone, while the curing adhesive ensures strong bonding to the cavity walls.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances the mechanical properties of structural components by ensuring effective reinforcement and sealing, even in difficult-to-access areas, while allowing for tailored mechanical properties through material selection.
Implementation Method 1
Foaming the foamable material (2) so that the fiber material is pressed against the inner wall of the cavity by the foamable material
Implementation Method 2
Curing the curing adhesive composition
Data Source
AI summary
The present invention relates to a reinforcement element (1) for reinforcement in cavities of structural components (6), which reinforcement element (1) is composed of a foamable material (2) and has, at its outer side, a fibrous material which is provided with a hardening adhesive compound. Here, the foamable material may be attached to a substrate part (4). Reinforcement elements according to the invention are used for example in structural components such as bodies and/or frames of means of transport and/or locomotive means.